ASM
Autoliv Supplier Manual
Training Chapter
Production Trial Runs (PTR):
Process and Templates
PRIVATE/PROPRIETARY
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
Training Background
Why does Autoliv require Production Trial Runs ?
• Verify & confirm information on actual part / process
•
•
•
•
evaluate performance as early as possible by First Trial Runs
check against specifications (PPAP Trial Runs)
ensure PPAP samples are run under serial conditions (PPAP Trial Runs)
measure actual cycle times / capacities by Run@Rate
What may happen if PTRs are not performed ?
• late PPAP approval
• endanger SOP
• increase amount of waste / scrap
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
Production Trial Run Participation & Documentation
CLD
PTR Requirements
1
documentation to be retained at supplier
2
documentation to be submitted to Autoliv
3&4
Autoliv participation at supplier, documents to be
submitted to Autoliv
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
1. Supplier First Production-Trial-Run
Project Time Line
„FirstOff-Tool“
Serial
order and
drawing
FirstProductionTrial-Run
Potential supplier internal
Production-Trial-Runs to
verify corrective actions.
Trial-Run-Modules
Forms /
Templates
1. Dimensional, Material,
Test Result Report
AIAG-Manual
PPAP
X
-
X
Production-TrialRun-Checklist
X
Production-TrialCapacity Report
X
3. Process-Quality-Audit
4. Capacity / Efficiency
Audit
PPAPSubmi
ssion
Run @ Rate
Corrective actions resulting from (First-)
Production-Trials
Production-Trial-RunRequirement-Matrix:
2. Capability Study
PPAPProductionTrial-Run
First-ProductionTrial-Run
X : Analysis and evaluation;
“out of specification” results allowed
Reviewing the PTR-modules and -templates through
examples on the following pages !
PRIVATE/PROPRIETARY
SOP
Production Trial Runs (PTR)
1. Supplier First Production-Trial-Run
Example:
• Specifications
(e.g. Drawings, DRDs, Standards)
• Tooling & Machine
• Raw Material
• Special Processes
(e.g. Heat Treatment, Coating)
• Inspection & Testing
• Operators
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PRIVATE/PROPRIETARY
Cold Forming
of Bolts
Production Trial Runs (PTR)
1. Supplier First Production-Trial-Run
Module 1.
Dimensional, Material, Test Result Report
Example:
Measure all dimensions and verify all drawing requirements !
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
1. Supplier First Production-Trial-Run
Module 2. Capability Study- Example:
The quality capability of a process is the comparison between the specified
performance and the actual performance.
Process capability is a powerful tool for predicting performance.
Lower Spec
Limit
Upper Spec
Limit
Lower Spec
Limit
Upper Spec
Limit
Specified performance
(voice of the customer)
Actual performance
(voice of the process)
For further explanations see AS 52 !
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
1. Supplier First Production-Trial-Run
Module 3. Production Trial Run Checklist (1)
Example:
Questionnaire
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
1. Supplier First Production-Trial-Run
Module 3. Production Trial Run Checklist (2)
Example:
Actions
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
1. Supplier First Production-Trial-Run
Module 4. Production Trial Run Capacity Report
Example:
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PRIVATE/PROPRIETARY
Production Trial Runs (PTR)
2. Supplier PPAP Production-Trial-Run
Project Time Line
„FirstOff-Tool“
Serial
order and
drawing
FirstProductionTrial-Run
Potential supplier internal
Production-Trial-Runs to
verify corrective actions.
PPAPProductionTrial-Run
Corrective actions resulting from (First-)
Production-Trials
Production-Trial-RunRequirement-Matrix:
Trial-Run-Modules
Forms /
Templates
1. Dimensional, Material,
Test Result Report
AIAG-Manual
PPAP
X
X
-
X
X
Production-TrialRun-Checklist
X
2. Capability Study
3. Process-Quality-Audit
4. Capacity / Efficiency
Audit
Production-TrialCapacity Report
First-Production- PPAP-ProductionTrial-Run
Trial-Run
X
X : Analysis and evaluation; “out of specification” results allowed
X
: Final verification; “out of specification” results NOT allowed
PRIVATE/PROPRIETARY
PPAPSubmi
ssion
Run @ Rate
SOP
Production Trial Runs (PTR)
3. Supplier Run@Rate
Project Time Line
„FirstOff-Tool“
Serial
order and
drawing
FirstProductionTrial-Run
Potential supplier internal
Production-Trial-Runs to
verify corrective actions.
PPAPProductionTrial-Run
PPAPSubmi
ssion
Run @ Rate
Corrective actions resulting from (First-)
Production-Trials
Production-Trial-RunRequirement-Matrix:
Trial-Run-Modules
Forms /
Templates
1. Dimensional, Material,
Test Result Report
AIAG-Manual
PPAP
X
X
-
X
X
Production-TrialRun-Checklist
X
X
Production-TrialCapacity Report
X
X
2. Capability Study
3. Process-Quality-Audit
4. Capacity / Efficiency
Audit
First-Production- PPAP-ProductionTrial-Run
Trial-Run
X : Analysis and evaluation; “out of specification” results allowed
X
: Final verification; “out of specification” results NOT allowed
PRIVATE/PROPRIETARY
Run @ Rate
SOP
Production Trial Runs (PTR)
Supplier Production-Trial-Run Conditions
Project Time Line
Serial
order and
drawing
„FirstOff-Tool“
FirstProductionTrial-Run
Potential supplier internal
Production-Trial-Runs to
verify corrective actions.
PPAPProductionTrial-Run
PPAPSubmi
ssion
Run @ Rate
SOP
Corrective actions resulting from (First-)
Production-Trials
Trial-Run-Conditions
First-Production- PPAP-ProductionTrial-Run
Trial-Run
Run @ Rate
Full ProductionSpeed
Serial Production Equipment / Site
Trial-Run Minimum Durance
Not specified
1 hour
4 -8 **
Minimum Number of parts produced
Not specified
300
Tbd **
All Shifts considered in Trial-Run(s)
Change-Over Procedures considered
Trained Operators
PPAP-ed Sub-Components
Control Plan
Pre-Launch
Serial Production ***
** The trials durance and the number of parts produced must be representative of serial conditions.
*** Serial Production Control Plan may be intensified (according to AS 412) upon Autoliv demand.
PRIVATE/PROPRIETARY
Serial Production ***
Demanded
Trial-Run
Condition
ASM: Supplier Production-Trial-Run Standard
Project Time Line
„FirstOff-Tool“
Serial
order and
drawing
FirstProductionTrial-Run
Production-Trial-RunRequirement-Matrix:
Potential supplier internal
Production-Trial-Runs to
verify corrective actions.
PPAPProductionTrial-Run
PPAPSubmi
ssion
Run @ Rate
Corrective actions resulting from (First-)
Production-Trials
Trial-Run-Modules
Forms /
Templates
1. Dimensional, Material,
Test Result Report
AIAG-Manual
PPAP
X
X
-
X
X
Production-TrialRun-Checklist
X
X
X
X
2. Capability Study
3. Process-Quality-Audit*
4. Capacity / Efficiency
Audit*
SOP
Production-TrialCapacity Report
First-Production- PPAP-ProductionTrial-Run
Trial-Run
Run @ Rate
X : Analysis and
evaluation; “out
of specification”
results allowed
X : Final
verification; “out
of specification”
results NOT
allowed
Full ProductionSpeed
Trial-RunConditions
Serial Production Equipment / Site
Trial-Run Minimum Durance
Not specified
1 hour
4 -8 **
Minimum No. of parts produced
Not specified
300
Tbd **
Demanded
Trial-Run
Condition;
All Shifts considered in Trial-Run(s)
Change-Over Procedures considered
Trained Operators
PPAP-ed Sub-Components
Control Plan
Pre-Launch
Serial Production ***
Serial Production ***
* : The whole, inhouse process chain must be considered for the audits. For capacity audit all potential bottle-neck processes must be investigated.
** : The trial‘s durance and the amount of parts produced must be representative of the process‘s serial conditions.
***: Serial Production Control Plan might be intensified (according to GP 12) upon Autoliv demand.
PRIVATE/PROPRIETARY